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Product: GAS ENGINE
Model: G3608 GAS ENGINE 4WF
Configuration: G3608 GENERATOR AND INDUSTRIAL January 1998 to
Current 4WF00001-UP

Operation and Maintenance Manual


G3606 and G3608 Engines
Media Number -SEBU6278-05

Publication Date -01/01/2005

Date Updated -13/01/2005


i02241623

Maintenance Interval Schedule - G3606 and G3608 Engines That


Have a 9.2:1 Compression Ratio and Use Wellhead or Natural
Gas
SMCS - 1000; 4450; 7500
Before performing any operation or maintenance procedures, ensure that the safety information,
warnings, and instructions are read and understood.
Before each consecutive interval is performed, all of the maintenance requirements from the previous
interval must be performed.
Note: For information on generator maintenance, see the Operation and Maintenance Manual for the
generator.

When Required
Actuator Control Linkage - Replace
Barring Device - Lubricate
Cooling System Coolant Sample (Level 2) - Obtain
Engine Air Cleaner Element (Single Element) - Clean/Replace
Engine Air Precleaner - Clean
Overhaul Considerations
Valve Stem Projection - Measure/Record

Daily
Air Starting Motor Lubricator Oil Level - Check
Air Tank Moisture and Sediment - Drain
Control Panel - Inspect
Cooling System Coolant Level - Check
Driven Equipment - Inspect/Replace/Lubricate
Electrohydraulic System - Inspect
Engine Air Cleaner Service Indicator - Inspect

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Engine Oil Level - Check


Fuel System Fuel Filter Differential Pressure - Check
Walk-Around Inspection

Every 250 Service Hours


Battery Electrolyte Level - Check
Cooling System Coolant Sample (Level 1) - Obtain
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
Engine Oil Sample - Obtain

Initial 1000 Service Hours


Air Starting Motor Lines Screen - Clean
Air Starting Motor Lubricator Bowl - Clean
Crankcase Blowby - Measure/Record
Cylinder Pressure - Measure/Record
Electrohydraulic System Oil Filter - Change
Engine Crankcase Breather - Clean
Engine Protective Device Connections - Inspect
Engine Valve Lash - Inspect/Adjust
Engine Valve Rotators - Inspect
Magnetic Pickups - Clean/Inspect
Valve Stem Projection - Measure/Record

Every 1000 Service Hours


Actuator Control Linkage - Lubricate
Belts - Inspect/Adjust/Replace
Hoses and Clamps - Inspect/Replace
Ignition System Spark Plugs - Check/Adjust

Every 2000 Service Hours


Aftercooler Condensation - Drain
Cooling System Coolant Sample (Level 2) - Obtain
Crankshaft Vibration Damper - Inspect
Engine Crankcase Breather - Clean
Engine Mounts - Check
Engine Valve Lash - Inspect/Adjust
Engine Valve Rotators - Inspect
Valve Stem Projection - Measure/Record

Every 5000 Service Hours


Air Starting Motor Lines Screen - Clean
Air Starting Motor Lubricator Bowl - Clean
Combustion Sensor - Clean/Inspect/Replace
Cooling System Level Switch - Inspect
Crankcase Blowby - Measure/Record

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Cylinder Pressure - Measure/Record


Driven Equipment - Check
Electrohydraulic System - Check/Adjust
Electrohydraulic System Oil - Change
Electrohydraulic System Oil Filter - Change
Engine Oil - Change
Engine Oil Filter - Change
Engine Protective Device Connections - Inspect
Engine Protective Devices - Check
Exhaust Bypass - Recondition
Gas Shutoff Valve - Inspect
Ignition System Spark Plugs - Replace
Inlet Air System - Inspect
Inlet Gas Manifold and Piping - Inspect/Replace
Magnetic Pickups - Clean/Inspect
Prechamber Check Valves - Clean
Starting Motor - Inspect
Turbocharger - Inspect

Every 10 000 Service Hours


Alternator - Inspect
Cooling System Water Temperature Regulator - Replace
Electrohydraulic Actuator - Inspect
Engine Oil Temperature Regulator - Replace
Exhaust Shields - Inspect
Gas Pressure Regulator - Inspect/Replace
Magneto Drive Coupling - Inspect
Prechamber Check Valves - Replace
Prelube Pump - Inspect
Water Pump - Inspect

Every 20 000 Service Hours or 3 Years


Cooling System Coolant (NGEC) - Change

Every 25 000 Service Hours


Gas Admission Valve Seals - Inspect/Replace
Overhaul (Top End)

Every 50 000 Service Hours


Electrohydraulic Actuator - Recondition
Gas Admission Valve - Recondition
Overhaul (In-Frame)

Every 100 000 Service Hours


Overhaul (Major)

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Overhaul
Connecting Rod Bearings - Inspect/Replace

Copyright 1993 - 2010 Caterpillar Inc.


All Rights Reserved.
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Sat Aug 28 11:24:09 UTC+0700 2010

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